Advances in Production of the Largest Military Aerospace Monolithic Titanium Forgings Eric Roegner President, Alcoa Forgings and Extrusions October 4 th and 5th International Titanium Association (ITA) Military Aerospace Panel 1
Alcoa at a Glance Founded in 1888 200+ locations 31 countries $18.4 billion 2009 revenue 10 times safer workplace than US average Award-winning sustainability leadership 120 years of aluminum technical leadership Number of Employees (2009) U.S. 23,000 Other Americas 19,000 Europe 10,000 Pacific 7,000 59,000
Covering Every Stage of Aluminum Production Leaders in Major End Markets Operations Upstream (41%) Bauxite mining Alumina refining Aluminum smelting Aluminum recycling Midstream (33%) Aluminum Sheet & Plate Aluminum Can Stock Downstream (26%) Fastening Systems Super-alloy castings Wheel & Transportation Building & Construction Forgings & Extrusions $7.5bn $6.1bn $4.8bn Primary Aluminum Transportation Packaging Building/ Construction Aerospace Industrial Oil & Gas Consumer Electronics
Alcoa Forgings and Extrusions Key Markets Automotive Industrial Industrial 13% Oil & Gas 1% Automotive 10% Defense 11% Aerospace 65% 2009 Data Oil and Gas Risers Aerospace Commercial & Defense Ground Defense Combat & Tactical Vehicles 4
Alcoa Forgings and Extrusions is a Global Organization 2400 employees - 9 plants - 4 countries Hannover Cleveland Lafayette Massena Chandler Halethorpe Samara Belaya Kalitva Changwon Alcoa Forgings and Extrusions Locations 5
Alcoa Titanium Die Forging History Alcoa has a rich history of producing large titanium forgings for the military and commercial industry over the past several decades Commercial Aero Die Forgings Titanium Hand Forgings Military Spars, Fittings, and Wing Box Military Die Forged Bulkheads 6
Development of the JSF Titanium Monolithic Bulkhead for the CTOL 496 In 2005, Alcoa began production JSF bulkheads in 7085 CTOL variant of the 496 bulkhead had to be titanium One of the largest dual sided die forging ever produced Proven monolithic design capabilities in previous forgings Excellent current engineering relationship with OEM, machine shops, and material suppliers to co-develop the single piece concept CTOL Bulkhead Materials 7085-T7452 CTOL 496 Titanium Bulkhead Ti-6-4 Eli
Development of the JSF Titanium Monolithic Bulkhead for the CTOL 496 This monumental forging was able to be produced start to finish within 28 weeks: Large hydraulic press capability Advanced segmented forging design and simulation Integrated titanium supply, partnerships and processing Controlled thermal processing and modeling technologies 15ft 6.5
Development of the JSF CTOL Bulkhead Alcoa Large Hydraulic Press Capability 50.000 ton press in Cleveland Press Rebuild on Track to be Complete EOY 2011 35,000 ton press in Cleveland Part Size: 354 in. L 120 in. W 65 in. height 30,000 pounds weight Plan View: 24,000 square inches Markets: Al. structural parts Land based turbine parts (Nickel-based super alloys) Ti structural parts Monolithic structures
Development of the JSF CTOL Bulkhead Integrated Titanium Supply & Processing Ingot Ingot Breakdown To Size Billet USI and Test Preform Block Forge Finish Forge Pre-machine Beta Anneal Entire Material Flow Path Through Forging is Fully Integrated with Partners for Fast Lead Times 10
Development of the JSF CTOL Bulkhead Thermal Processing and Modeling technologies Proper beta-anneal must be assured within such large structures Careful process control and design must be established Proper pre-machine configuration and racking Proper beta anneal cycle modeling Alcoa worked closely with the machine shop, OEM, Air Force, and Navy to assure proper development of the thermal cycles Thermal Modeling Utilized To Develop Proper Beta Anneal Cycle Based on Geometry
Development of the JSF CTOL Bulkhead Quickest Lead Times Leads to First Build CV Structures Based on the Alcoa Advantages, the CTOL 496 bulkhead was produced in 28 Weeks Alcoa s success on the CTOL 496 bulkheads led to Alcoa next producing the largest CV titanium forgings (CV 496 even bigger) 1 st Piece Finish Forged For CTOL 496 JSF CV Variant Monolithic Ti Forgings Produced by Alcoa for SDD Rear Spars 496 & 556 BH Root Ribs Largest Titanium Die Forgings Front Spars Alcoa is a proven industry leader in the design, development, and manufacturer of large monolithic titanium structures 12
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